U.S. patent application number 11/180140 was filed with the patent office on 2007-01-18 for underbalanced drilling applications hydraulically operated formation isolation valve.
Invention is credited to Fredrick D. Curtis, Michael Harvey, Ronald Hyden, James D. JR. Vick, Jimmie R. JR. Williamson.
Application Number | 20070012457 11/180140 |
Document ID | / |
Family ID | 37084855 |
Filed Date | 2007-01-18 |
United States Patent
Application |
20070012457 |
Kind Code |
A1 |
Curtis; Fredrick D. ; et
al. |
January 18, 2007 |
Underbalanced drilling applications hydraulically operated
formation isolation valve
Abstract
A formation isolation valve for underbalanced drilling
applications. A system for operating a formation isolation valve
includes the valve interconnected in a casing string. An assembly
displaces through the casing string, thereby causing the valve to
open prior to the assembly reaching the valve. An operating system
includes a well tool with an actuator positioned downhole. A device
for causing the actuator to operate the well tool is also
positioned downhole remote from the actuator. A method of operating
a well tool includes the steps of: positioning the well tool in a
well, the well tool including an actuator; positioning a power
source for the actuator in the well; and at a downhole position
remote from the actuator, causing the actuator to operate the well
tool.
Inventors: |
Curtis; Fredrick D.;
(Stafford, TX) ; Hyden; Ronald; (Spring, TX)
; Harvey; Michael; (Granite Shoals, TX) ;
Williamson; Jimmie R. JR.; (Carrollton, TX) ; Vick;
James D. JR.; (Dallas, TX) |
Correspondence
Address: |
SMITH IP SERVICES, P.C.
660 NORTH CENTRAL EXPRESSWAY
SUITE 230
PLANO
TX
75074
US
|
Family ID: |
37084855 |
Appl. No.: |
11/180140 |
Filed: |
July 13, 2005 |
Current U.S.
Class: |
166/386 ;
166/66.5 |
Current CPC
Class: |
E21B 47/12 20130101;
E21B 34/14 20130101; E21B 21/085 20200501; E21B 23/00 20130101 |
Class at
Publication: |
166/386 ;
166/066.5 |
International
Class: |
E21B 31/06 20060101
E21B031/06 |
Claims
1. A method of operating a well tool in a well, the method
comprising the steps of: positioning the well tool in the well, the
well tool including an actuator; positioning a power source for the
actuator in the well; and at a downhole position in the well remote
from the actuator, causing the actuator to operate the well
tool.
2. The method of claim 1, wherein the well tool is interconnected
in a tubular string, and further comprising the steps of installing
an assembly in the tubular string and displacing the assembly to
the downhole position to operate the well tool.
3. The method of claim 2, wherein the step of causing the actuator
to operate the well tool is performed without requiring physical
contact between the assembly and the tubular string at the downhole
position.
4. The method of claim 2, wherein the well tool is a valve which
selectively permits and prevents flow through the tubular
string.
5. The method of claim 4, wherein the assembly is a drill string,
and wherein the displacing step further comprises displacing the
drill string through the valve.
6. The method of claim 1, wherein the step of causing the actuator
to operate the well tool further comprises forming a magnetic
coupling in the well.
7. The method of claim 6, wherein the well tool is interconnected
in a tubular string, and wherein the step of causing the actuator
to operate the well tool further comprises displacing an assembly
through the tubular string to thereby cause the magnetic coupling
to displace.
8. The method of claim 7, wherein the assembly displacing step
further comprises displacing a first magnetic device carried on the
assembly.
9. The method of claim 1, wherein the power source is a pump.
10. The method of claim 9, wherein the step of causing the actuator
to operate the well tool further comprises displacing an assembly
through a tubular string in which the well tool is interconnected,
thereby causing fluid transfer between the pump and the
actuator.
11. A well tool operating system, comprising: a well tool including
an actuator positioned downhole in a well; and a device for causing
the actuator to operate the well tool, the device being positioned
downhole in the well and remote from the actuator.
12. The system of claim 11, wherein the device includes a magnetic
coupling.
13. The system of claim 12, wherein the well tool is interconnected
in a tubular string, and wherein displacement of an assembly
through the tubular string operates the magnetic coupling, thereby
causing the actuator to operate the well tool.
14. The system of claim 11, further comprising a power supply, and
wherein the device causes the power supply to supply power to the
actuator.
15. The system of claim 14, wherein the power supply is a pump.
16. A system for operating a formation isolation valve, the system
comprising: the formation isolation valve interconnected in a
casing string and positioned downhole in a well; and an assembly
which displaces through the casing string, displacement of the
assembly through the casing string causing the valve to open prior
to the assembly reaching the valve.
17. The system of claim 16, wherein displacement of the assembly
through the casing string operates a magnetic coupling.
18. The system of claim 16, wherein displacement of the assembly
through the casing string operates a pump, thereby causing fluid
transfer between the pump and an actuator of the valve.
19. The system of claim 16, wherein displacement of the assembly
through the casing string activates a device positioned remote from
an actuator of the valve, and wherein activation of the device
causes the actuator to open the valve.
20. The system of claim 16, wherein displacement of the assembly
through the casing string causes the valve to open without physical
contact between the valve and the assembly.
Description
BACKGROUND
[0001] The present invention relates generally to operations
performed and equipment utilized in conjunction with a subterranean
well and, in an embodiment described herein, more particularly
provides a formation isolation valve for use in underbalanced
drilling applications.
[0002] A formation isolation valve is typically used in
underbalanced drilling operations to close off flow through a
casing string while tripping a drill string, or otherwise when
access to a wellbore below the valve is not required. The valve is
opened when the drill string or other assembly (such as wireline
tools, coiled tubing string, etc.) needs to be displaced downwardly
through the valve. The valve is then closed when the assembly is
displaced upwardly through the valve.
[0003] Some formation isolation valves are operated hydraulically
using control lines which extend to the surface. Pressure applied
to the control lines at the surface is used to open and close such
valves. However, these long control lines have significant
disadvantages. For example, long control lines are expensive to
purchase and install, long control lines have increased
susceptibility to damage during installation and leakage
thereafter, etc.
[0004] Some formation isolation valves are operated by physical
contact between the valve and the assembly as it is displaced
through the valve. The assembly may engage and shift a sleeve or
other device which causes a closure member of the valve to open.
This physical contact has the disadvantage that it usually requires
relatively small clearance between the valve and the assembly,
which leads to a restriction in the interior of the valve.
[0005] Therefore, it may be seen that improvements are needed in
the art. It is one of the objects of the present invention to
provide such improvements. These improvements may also be useful in
applications other than formation isolation valves for
underbalanced drilling.
SUMMARY
[0006] In carrying out the principles of the present invention,
methods and systems are provided which solve at least one problem
in the art. One example is described below in which an actuator for
a downhole well tool is remotely activated without the use of long
control lines extending to the surface. Another example is
described below in which the actuator is remotely activated without
requiring any physical contact between the well tool and an
assembly displaced through the well tool.
[0007] In one aspect of the invention, a method of operating a well
tool in a well is provided. The method includes the steps of:
positioning the well tool in the well, the well tool including an
actuator; positioning a power source for the actuator in the well;
and at a downhole position in the well remote from the actuator,
causing the actuator to operate the well tool.
[0008] In another aspect of the invention, a well tool operating
system is provided which includes a well tool with an actuator
positioned downhole in a well. A device for causing the actuator to
operate the well tool is also positioned downhole in the well.
However, the device is positioned remote from the actuator.
[0009] In yet another aspect of the invention, a system for
operating a formation isolation valve is provided. The system
includes the formation isolation valve interconnected in a casing
string and positioned downhole in a well. An assembly displaces
through the casing string, such that displacement of the assembly
through the casing string causes the valve to open prior to the
assembly reaching the valve.
[0010] These and other features, advantages, benefits and objects
of the present invention will become apparent to one of ordinary
skill in the art upon careful consideration of the detailed
description of representative embodiments of the invention
hereinbelow and the accompanying drawings, in which similar
elements are indicated in the various figures using the same
reference numbers.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a schematic partially cross-sectional view of a
method of operating a well tool, the method embodying principles of
the present invention;
[0012] FIG. 2 is an enlarged scale schematic cross-sectional view
of a device which may be used to remotely activate an actuator of a
well tool in the method of FIG. 1;
[0013] FIG. 3 is a schematic cross-sectional view of a well tool
including an actuator which may be used in the method of FIG. 1;
and
[0014] FIG. 4 is a schematic cross-sectional view of an alternate
construction of the device of FIG. 2.
DETAILED DESCRIPTION
[0015] Representatively illustrated in FIG. 1 is a method 10 which
embodies principles of the present invention. In the following
description of the method 10 and other apparatus and methods
described herein, directional terms, such as "above", "below",
"upper", "lower", etc., are used for convenience in referring to
the accompanying drawings. In general, the downward direction is
illustrated as being further from the earth's surface along a
wellbore, and the upward direction is illustrated as being toward
the surface, but it will be appreciated by those skilled in the art
that, in actual practice, wellbores are seldom consistently
vertical.
[0016] Additionally, it is to be understood that the various
embodiments of the present invention described herein may be
utilized in various orientations, such as inclined, inverted,
horizontal, vertical, etc., and in various configurations, without
departing from the principles of the present invention. The
embodiments are described merely as examples of useful applications
of the principles of the invention, which is not limited to any
specific details of these embodiments.
[0017] As depicted in FIG. 1, an assembly 12 is being displaced
downwardly through a tubular string 14. The assembly 12 is
illustrated as comprising a drill string 16 having a drill bit 18
at a lower end. The drill string 16 may also include many other
elements, such as a mud motor 20, etc.
[0018] The tubular string 14 is illustrated as comprising a casing
string 22 which is cemented in a wellbore 24. As used herein, the
term "casing string" is used to indicate any type of tubular string
which is used to form a protective lining for a wellbore, and the
term can include liner strings and other types of tubular strings
made of any type of material.
[0019] A well tool 26 is interconnected in the casing string 22.
The well tool 26 is illustrated as comprising a formation isolation
valve 28. As the drill string 16 displaces downward toward the
valve 28, the valve opens prior to the drill string reaching the
valve.
[0020] Although the method 10 is described as including the step of
displacing the drill string 16 through the casing string 22 to
operate the valve 28, it should be clearly understood that this is
only one example of an application of the principles of the
invention. The assembly 12 is not necessarily a drill string (for
example, the assembly could be a wireline conveyed tool, a coiled
tubing string, or any other type of assembly). The assembly 12 does
not necessarily have to be displaced through the tubular string 14.
The tubular string 14 is not necessarily a casing string (for
example, the tubular string could be a production tubing string, a
coiled tubing string, or any other type of tubular string). The
well tool 26 is not necessarily a formation isolation valve or any
other type of valve (for example, the well tool could be a choke, a
packer, a pump, a hanger, or any other type of well tool). Thus, it
will be appreciated that the method 10 is but one example of a very
wide variety of uses for the principles of the invention.
[0021] One of the important features of the method 10 is that the
valve 28 is remotely operated, so that direct physical contact is
not required between the valve and the drill string 16. Another
important feature is that this remote operation is accomplished in
the method 10 without requiring the use of long control lines
extending from the surface to the valve 28.
[0022] The remote operation is accomplished in the method 10 by
interconnecting a device 30 in the casing string 22 above the valve
28. For example, the device 30 may be remotely positioned a
distance L1 above the valve 28. As the drill string 16 displaces
through the device 30, the device causes an actuator of the valve
28 to operate the valve. In this manner, the device 30 activates
the actuator (thereby causing the valve 28 to open) prior to the
drill string 16 reaching the valve.
[0023] Preferably, the drill string 16 includes a device 32 which
interacts with the device 30 to activate the actuator of the valve
28. The device 32 may be located a distance L2 above the lower end
of the drill bit 18, with the distance L2 being less than the
distance L1, so that the devices 30, 32 interact to activate the
actuator to open the valve, prior to the drill bit reaching the
valve 28 (or a closure member of the valve).
[0024] When the drill string 16 is displaced upwardly through the
valve 28, the devices 30, 32 interact to activate the actuator to
close the valve. In this manner, the valve 28 closes after the
drill bit 18 has passed upwardly through the valve, thereby
isolating a formation intersected by the wellbore 24 below the
valve.
[0025] The device 30 is depicted in FIG. 1 as being connected to
the valve 28 using lines 34 extending between the device and the
valve external to the casing string 22. The lines 34 are described
in more detail below as including hydraulic lines, but any type of
communication between the device 30 and the valve 28 could be used
(for example, pneumatic lines, electrical lines, optical lines, any
form of telemetry (acoustic, electromagnetic, pressure pulse,
etc.)) in keeping with the principles of the invention. It also is
not necessary for the lines 34 to extend external to the casing
string 22, since they could also, or alternatively, extend internal
to the casing string, within a sidewall of the casing string, etc.,
or the lines may not be used at all if telemetry is used to
communicate between the device 30 and the valve 28.
[0026] Referring additionally now to FIG. 2, an enlarged schematic
cross-sectional view of one possible construction of the device 30
is depicted with the assembly 12 being displaced through the
device. In this construction of the device 30, a magnetic coupling
is created between the assembly 12 and the device 30 in order to
operate a power source 36 in the device.
[0027] The power source 36 includes a piston 38 reciprocably
received in a bore 40 formed in an outer housing assembly 76 of the
device 30. Thus, in this embodiment the power source 36 is a pump
used to create a pressure differential to operate the valve 28.
However, other types of power sources (such as electrical,
mechanical, thermal, optical and other types of power sources) may
be used in keeping with the principles of the invention.
[0028] The piston 38 is on a rod 42 which is attached to a
cylindrical sleeve 44. A stack of annular shaped magnets 46 is
carried on the sleeve 44.
[0029] The device 32 also includes a stack of annular shaped
magnets 48 carried on the assembly 12. When the assembly 12 is
displaced through the device 30, a magnetic coupling is created
between the magnets 46, 48. This magnetic coupling permits a
biasing force to be transmitted between the devices 30, 32 without
requiring any physical contact.
[0030] When the magnetic coupling is created as depicted in FIG. 2
and the assembly 12 is displaced downward, a biasing force is
exerted on the piston 38 (via the magnets 46, sleeve 44 and rod 42)
to also displace the piston downward. This downward displacement of
the piston 38 in the bore 40 causes a pressure differential to be
created between lines 50, 52 connected to the device 30.
[0031] Specifically, pressure in the line 52 will be increased
relative to pressure in the line 50. Of course, if the assembly 12
is displaced upwardly through the device 30, the magnetic coupling
will be used to bias the piston 38 upward and thereby increase
pressure in the line 50 relative to pressure in the line 52.
[0032] The lines 50, 52 may be included in the lines 34 depicted in
FIG. 1. Since these lines 50, 52 only extend a relatively short
distance (for example, approximately 20-30 meters) between the
device 30 and the valve 28, they are significantly less susceptible
to damage and leakage, and less expensive to purchase and install,
as compared to control lines which extend perhaps thousands of
meters to the surface.
[0033] Another beneficial feature of the device 30 is a balance
piston 54 which ensures that pressure in an internal chamber 56 of
the device 30 is equalized, via an opening 62, with pressure in an
internal passage 58 through which the assembly 12 is displaced. In
this manner, a wall 60 separating the magnets 46, 48 can be made
relatively thin (since it does not have to withstand a large
pressure differential), thereby increasing the biasing force which
may be transmitted by the magnetic coupling.
[0034] Although the devices 30, 32 are illustrated as including
magnets 46, 48 for transmitting a biasing force to the pump 36,
these particular elements are not necessary in keeping with the
principles of the invention. A magnetic field may be produced
without the use of permanent magnets, for example, by using an
electric coil, magnetostrictive materials, etc. A biasing force may
be transmitted using a magnetic coupling without use of permanent
magnets, for example, by using magnetostrictive materials,
solenoids, etc.
[0035] Furthermore, it is not necessary for a magnetic coupling to
be used at all. A construction is illustrated in FIG. 4 and
described below in which no magnetic coupling is used.
[0036] Referring additionally now to FIG. 3, a schematic
cross-sectional view of the valve 28 is representatively
illustrated. The valve 28 includes an actuator 64 and a closure 66
for selectively permitting and preventing flow and access through a
passage 68 formed through the valve.
[0037] The actuator 64 includes a sleeve 70 reciprocably and
sealingly received in an outer housing assembly 74 of the valve 28.
A radially enlarged piston 72 is formed on the sleeve 70. The lines
50, 52 are connected to the actuator 64 so that they communicate to
below and above the piston 72, respectively. Thus, increased
pressure in the line 52 relative to pressure in the line 50 will
bias the sleeve 70 downward, and increased pressure in the line 50
relative to pressure in the line 52 will bias the sleeve
upward.
[0038] The closure 66 includes a member 80 which functions to seal
off the passage 68. The member 80 is illustrated as being a
flapper, but it could be any type of sealing member, such as a
ball, etc. The member 80 is preferably biased toward a closed
position as shown in FIG. 3, for example, by use of a biasing
device (such as a spring, gas charge, etc., not shown).
[0039] With the sleeve 70 in its upper position, the closure 66 is
closed. When pressure in the line 52 is increased relative to
pressure in the line 50 (by downwardly displacing the piston 38 as
described above), the sleeve will displace downward. This downward
displacement of the sleeve 70 will cause the closure 66 to open,
for example, by pivoting the member 80 so that it no longer blocks
access and flow through the passage 68.
[0040] When pressure in the line 50 is increased relative to
pressure in the line 52 (by upwardly displacing the piston 38 as
described above), the sleeve will displace upward. This upward
displacement of the sleeve 70 will cause the closure 66 to close,
for example, by allowing the member 80 to pivot across the passage
68 and again block flow and access through the passage.
[0041] A mechanism (not shown) may be provided for releasably
maintaining the sleeve 70 in its upper and/or lower position. For
example, a spring or other biasing device could be used to prevent
the sleeve 70 from displacing downward due to its own weight when
it is desired to keep the valve 28 closed. Alternatively, or in
addition, a detent mechanism (such as a snap ring, collet, spring
loaded detent, etc.) could be used to releasably secure the sleeve
70 in its upper and/or lower position.
[0042] Referring additionally now to FIG. 4, a schematic
cross-sectional view of an alternate construction of the device 30
is representatively illustrated. This alternate construction is
similar in many respects to the construction depicted in FIG. 2,
and so the same reference numbers are used in FIG. 4 to indicate
similar elements.
[0043] One significant difference between the constructions
depicted in FIGS. 2 & 4 is that, instead of the wall 60, the
construction of FIG. 4 has a sleeve 82 reciprocably and sealingly
received in the housing assembly 76. The sleeve 82 is connected to
the rod 42 so that the piston 38 displaces with the sleeve.
[0044] Another significant difference is that no magnetic coupling
is used in the construction of FIG. 4. Instead, the assembly 12
biases the sleeve 82 to displace via engagement with a recessed
profile 84 formed in the sleeve. The device 32 includes a key, dog
or other engagement member 86 for engaging the profile 84.
[0045] As the assembly 12 displaces downwardly through the device
30, the member 86 engages the profile 84, thereby transferring a
downward biasing force from the assembly to the sleeve 82. The
piston 38 displaces downward with the sleeve 82, thereby increasing
pressure in the line 52 relative to pressure in the line 50 and
causing the actuator 64 to open the closure 66. The assembly 12 can
then displace downward through the open valve 28.
[0046] Upward displacement of the assembly 12 through the device 30
will again cause the member 86 to engage the profile 84, thereby
transferring an upward biasing force from the assembly to the
sleeve 82. The piston 38 will displace upward with the sleeve 82,
thereby increasing pressure in the line 50 relative to pressure in
the line 52 and causing the actuator 64 to close the closure 66.
The valve 28 will thus close after the assembly 12 has displaced
through the valve.
[0047] Multiple openings 62 may be used to provide communication
between the passage 58 and the balance piston 54. Filtering may be
provided for the openings 62 to prevent debris, etc. from passing
through the openings.
[0048] The alternate constructions of FIGS. 2 & 4 demonstrate
that the invention may be practiced in a variety of different
forms, and with or without use of a magnetic coupling. Use of the
pump 36 to transfer fluid between the device 30 and the actuator 64
is also not required. For example, the actuator 64 could instead be
an electrical actuator and the device 30 could include an
electrical switch, so that when the assembly 12 displaces through
the device, the switch is activated and causes electrical current
to flow in the actuator to operate the valve 28.
[0049] If a magnetic coupling is used, the magnetic coupling could
be used to activate an electrical switch or other device, instead
of a pump.
[0050] It is not necessary for magnets to be carried on the
assembly 12 if a magnetic coupling is used. For example, a sleeve
which carries magnets thereon could be reciprocably mounted in the
casing string 22. The magnets on this internal sleeve could be
magnetically coupled to the magnets 46 carried on the sleeve 44 on
an opposite side of the wall 60 (as in the construction of the
device 30 depicted in FIG. 2). The assembly 12 as depicted in FIG.
4 could then be used to shift the internal sleeve (i.e., by
engaging the member 86 with a profile formed in the sleeve) to
cause displacement of the piston 38 or operation of an electrical
switch, etc. to activate the actuator 64.
[0051] Another alternate construction could be used in which a
radioactive source is carried on the assembly 12. The device 30
could include a radiation detector (for example, a gamma ray
detector) to sense the presence of the radioactive source. When the
radioactive source is detected, the device 30 could cause the
actuator 64 to open or close the closure 66 as appropriate.
[0052] Another alternate construction could be used in which the
device 30 includes a density sensor for detecting density in the
passage 58. When the density sensor senses an increased density
(due to the presence of the assembly 12 in the passage 58), the
device 30 could cause the actuator 64 to open the closure 66. When
the density sensor senses a decreased density (due to an absence of
the assembly 12 in the passage 58) the device 30 could cause the
actuator 64 to close the closure 66.
[0053] Of course, a person skilled in the art would, upon a careful
consideration of the above description of representative
embodiments of the invention, readily appreciate that many
modifications, additions, substitutions, deletions, and other
changes may be made to these specific embodiments, and such changes
are within the scope of the principles of the present invention.
Accordingly, the foregoing detailed description is to be clearly
understood as being given by way of illustration and example only,
the spirit and scope of the present invention being limited solely
by the appended claims and their equivalents.
* * * * *